Wilbur Curtis Company, Inc. Service Manual – G4 Milano Twin Brewer Important Safeguards/Symbols This equipment is designed for commercial use. Any servicing other than cleaning and routine maintenance should be performed by an authorized Wilbur Curtis Company Service Technician. • DO NOT immerse the unit in water or any other liquid • To reduce the risk of fire or electric shock, DO NOT open service panels. There are no user serviceable parts inside. • Keep hands and other items away from hot areas of the unit during operation. • Never clean with scouring powders or harsh chemicals. Symbols: WARNINGS – To help avoid personal injury Important Notes/Cautions – from the factory Sanitation Requirements This Curtis Generation 4 Unit is Factory Pre-Set and Ready to Go Right from the Box. Following are the Factory Settings for your G4 Coffee Brewing System: Model G4TPC2T CAUTION: Please use this setup procedure before attempting to use this brewer. Failure to follow the instructions can result in injury or the voiding of the warranty. IMPORTANT: Equipment to be installed to comply with applicable governmental plumbing/electrical codes having jurisdiction. CAUTION: DO NOT connect this brewer to hot water. The inlet valve is not rated for hot water. • Brew Temperature = 200°F • Water Bypass = On for LARGE & MEDIUM Brew Only • Brew Volume = Set to Vessel Requirement. System Requirements: • Water Source 20 – 90 PSI (Minimum Flow Rate of 1 GPM) • Electrical: See attached schematic for standard model or visit www.wilburcurtis.com for your model. SETUP STEPS 1. The unit should be level (left to right - front to back), on a secure surface. 2. Connect the water line to the water inlet fitting on the rear of the unit. Water volume flow to the machine should be consistent. Use tubing sized sufficiently to provide a minimum flow rate of one gallon per minute. NOTE: A water filtration system must be used to help maintain trouble-free operation. In areas with extremely hard water, we highly recommend the use of a Curtis approved water filter. For our full line of filters, please log on to www.wilburcurtis.com. A water filtration system will greatly prolong the life of the unit and enhance the quality and taste of the product. NSF International requires the following water connection: 1. A quick disconnect or additional coiled tubing (at least 2x the depth of the unit) is required so that the unit can be moved for cleaning. 2. This unit must be installed with adequate backflow protection to comply with applicable federal, state and local codes. 3. Water pipe connections and fixtures directly connected to a portable water supply shall be sized, installed and maintained in accordance with federal, state, and local codes. 3. Connect the unit to electrical outlet with appropriate amperage rating (see serial tag on machine). 4. Once power has been supplied to the unit, flip the toggle switch to the ‘ON’ position (located on the rear of the unit), the water tank will begin to fill. When the water level in the tank reaches the probe, the heating element(s) will turn on. ISO 9001:2008 REGISTERED WILBUR CURTIS CO., INC. 6913 West Acco Street Montebello, CA 90640-5403 For the latest information go to www.wilburcurtis.com Tel: 800-421-6150 Fax: 323-837-2410 5. Water in the heating tank will require approximately a half hour before reaching operating temperature (factory setting of 200°F). Where applicable, turn on the Universal Control Module (UCM). When the unit reaches operating temperature, it will display “READY TO BREW”. For the latest specifications and information go to www.wilburcurtis.com Technical Support: 1-800-995-0417 M-F 5:30am-4:00pm PT Email: techsupport@wilburcurtis.com 1 Your Curtis G4/Gold Cup Series is Factory Pre‑Set for Optimum Performance. After connection to water and power; turn on the brewer at the rear toggle switch. You will hear a beep and the status lights will come on for a moment. The screen will display MODEL NUMBER CONTROL BD NUMBER When the proper level is reached FILLING . Next HEATING is displayed. Water will fill the tank (2-3 minutes depending on water flow rate). will appear on the screen. It takes approximately 30 minutes to reach the set point temperature. Control will display READY TO BREW when temperature reaches the set point. The unit is now ready to brew. COFFEE BREWING INSTRUCTIONS 1. Brewer should be ON (Confirm at the rear toggle switch). The LCD screen should read Ready to Brew. 2. Place an empty Milano 1½ gallon server under the brew cone. 3. Place a clean filter into the brew cone. 4. Fill brew cone with ground coffee. 5. Transfer filled brew cone to brewer. 6. Touch desired brew button. Brewing will begin immediately. WARNING TO AVOID SCALDING, Do not remove brew cone while brew light is flashing. Touch Screen Control Module The touch screen turns on when power is available to the controller. The screen will contain standard control feature such as symbols and buttons. Pressing these elements with your finger tip will activate the programming functions. The default screen, as well as some added control buttons are shown in the illustration below. STATUS LIGHTS BREW BUTTONS CURTIS LOGO TO ENTER PROGRAMMING Tap Curtis logo 5 times to bring up the ACCESS CODE screen. CONTROL SYMBOLS All of these symbols may not be visible at one time. 2 RETURN TO HOME UNDO SCROLL RETURN TO PREVIOUS PROGRAMMING ACCESS CODE screen. Default is 1 2 3 4. Once the code is entered, press OK. The Main Menu screen will appear. MAIN MENU screen contains five control icons: RECIPES, CONTROL SETTINGS, BREW SETTINGS, MODEL SELECT and EXIT. Menu Tree This chart explains how to enter the program mode and menu selections available from the MAIN MENU. Tap "Curtis" Logo 5 Times to Enter Programming Mode Enter 1-2-3-4 to access the Main Menu Gourm e t STD Te m p Se tti ngs Se l e ct Button… Light Roa st W a rm e r Se tti ngs Bre w By Vol um e Da rk Roa st Qua l i ty Ti m e r Bre w By Ti m e Hi gh Yi e l d Ene rgy Sa vi ng Pre -I nfusi on Fi l te r Pa ck S ounds Pulse Bre w On/Off De ca f Di a gnosti cs Bypa ss On/ Off Hom e Di spl a y Se tti ngs Dri p Out Pre v - Ma i nt Hom e Gemini S i ngl e One Ba tch Tw i n Tw o Ba tch Gemini IF Three Batch Thermopro Milano Si ngl e Cup Ce ra m i c Cup Thre e Ba tch Paper Cup Brew Counter Passwords Master Reset Home 3 Menu Features 4 Menu Features 5 System Fault Messages WARNING MESSAGES - ALLOWS BREWING MESSAGE DISPLAY Component Failure Service Required 1-(800)-000-0000x WARNING DESCRIPTION CAUSE A Component has Failed Current in one of the components is not within normal range. Maintenance Required Service Required 1-(800)-000-0000x Maintenance Required Lime Scale Warning Service Required 1-(800)-000-0000x Scale Starting to Build Up Water Level Probe Low Water Flow Warning Service Required 1-(800)-000-0000x Low Water Flow Brew count "Gallons Since Reset" exceeds programmed Preventative Maintenance period Water level probe resistance above warning threshold (test value 23k Ohm) If the Inlet valve remains on longer than 40 Seconds (during the brew cycle only) and repeats TWICE during that brew cycle. It shall clear upon the next brew and if the same low flow exists again, it will re-appear. ERROR MESSAGES - STOPS BREWING MESSAGE DISPLAY 6 ERROR DESCRIPTION CAUSE Water Level Error Service Required 1-(800)-000-0000x Fill run error / Overflow Sensor Error Service Required 1-(800)-000-0000x Open Sensor Break in the temperature thermistor circuit or short curcuit. Over Temp. Error Service Required 1-(800)-000-0000x Excess Temperature The sensor is reading that temperature in the heating tank has risen above 210ºF, or sensor has shorted to ground. Lime Scale Error Service Required 1-(800)-000-0000x Probe Water level probe resistance above error threshold (test value 180kOhm) Internal Error 1 Service Required 1-(800)-000-0000x UPM-UCM Communication The fill solenoid has either run for more than 10 minutes on the initial tank fill or 1.5 minutes in normal operation Break in the UPM-UCM Communication circuit. Illustrated Parts Main View 1 2 13 14 15 16 3 4 5 17 7 8 9 1 6 11 12 42 7 Illustrated Parts Heating Tank 18 19 20 21 22 23 24 25 26 27 28 8 Illustrated Parts Top Wrap 29 30 31 32 33 34 3 3 40 41 3 3 39 9 Parts List ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 12A 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 PART NO. WC-61289 WC-61284 WC-61286 WC-1853* WC-37259* WC-37308* WC-14045-101* WC-8559* WC-3528 WC-61290 WC-61287 GEM-6 * GEM-6-101* WC-2402P* WC- 847* WC-1501 WC- 102* WC-61285 WC-37008* WC-37406* WC-43067* WC-5350* WC-5310* WC-62030* WC- 934-04* WC-1438-101* WC-4382 WC- 522 WC-43055 WC- 821WDR* WC- 442* WC- 589-101 WC-844-101* WC-13450 WC- 820WDR* WC-2977-101* WC-4306-103* WC-4212-02 WC-29050 WC-10008 WC-39811 WC-10000* WC-10001* DESCRIPTION COVER, TOP PANEL, L SHAPE, LEFT PANEL, CENTER SECTION, LEFT FAUCET, ASSY TPC (MILANO) KIT, BREW CONE GOURMET NON-METAL WITH “FRESH COFFEE” LOGO KIT, BREW CONE GEMINI NON-METAL WITH “FRESH COFFEE” LOGO CURRENT SENSOR ASSY G4 RELAY, SOLID STATE 40A w/INTEGRATED HEATSINK LEG, 4” ADJUSTABLE 3/8-16 THREAD STYLIZED COVER, CENTER WRAP PANEL, INTERSECTION, RIGHT FILTER, 500PK GEM-12/230A FILTER, PAPER 15 x 5-1/2 x 4-3/4 ELBOW, 3/8 NPT x 3/8 FLARE PLATED VALVE, INLET 2 GPM 120V-10W FUSE, HOLDER ASSY w/5A FUSE SWITCH, TOGGLE SPST 15A 125Vac RESISTIVE PANEL, L SHAPE, RIGHT KIT, TANK LID ROUND KIT, LIQUID LEVEL PROBE FAIL SAFE NON-METAL GEN O-RING, 4-1/2 I.D. x Ø.285 C.S. SILICONE TUBE, SILICONE Ø1/2” ID x Ø3/4” OD x 1/8” WALL TUBE, SILICONE Ø5/16” ID x Ø9/16” OD x 1/8” WALL TANK COMPLETE, 220V, (3) 2500W ELEMENT, 6.89 GALLONS KIT, ELEMENT HEATING 2.5KW 220V W/ JAM NUT & SILICONE WASHERS SENSOR, TEMPERATURE TANK GUARD, SHOCK (HEATING ELEMENT) THERMOSTAT, HI LIMIT HEATER DPST 277V-40A GUARD, SHOCK RESET THERMOSTAT VALVE, DUMP LEFT 120V-14W w/INTERNAL RESISTOR & DIODE SOLENOID, LOCK BREW CONE RIGHT 120VAC TRANSFORMER, 120/230VAC - 24VAC 4.8VA w/LEADS & TERMINALS VALVE, BYPASS 120V-14W NON ADJUSTABLE w/RESTRICTOR (WC-2945) HARNESS ASSY, COMPLETE TP2T10G4/GEMTS10G4/GEMTIF10G4 VALVE, DUMP RIGHT 120V-14W w/INTERNAL RESISTOR & DIODE FITTING, SPRAYHEAD ULTEM WASHER, 7/8OD x 9/16ID x 3/32 THK, SNGL-D, SILICONE NUT, 5/8-18 JAM PLASTIC-ULTEM SPRAYHEAD ASSY, AFS-AMBER UNIVERSAL HOST ADAPTER (USB) LABEL, OUTER TOUCH SCREEN TP2T CURTIS LOGO CONTROL MODULE, TOUCH SCREEN G4 UNIVERSAL POWER MODULE - G4 * RECOMMENDED PARTS TO STOCK 10 Electrical Schematic G4 Milano Twin 11 Cleaning and Sanitizing Instructions for Milano Server CAUTION Do not immerse in water. Do not place in dishwasher. Do not use harsh powders or cleansers containing chlorine. Do not use a wire brush or pot scourer to clean inside liner. These cleaning and sanitizing instructions are only a guide line to be used for the cleaning and sanitizing of the ThermoPro server. Your current in-house cleaning and sanitizing methods may be just as effective. For cleaning and sanitizing of the server, the three sink method is recommended. This method consists of a sink with a detergent and water solution, a fresh water rinse, and a sink filled with an aqueous sanitizing solution. Immerse in commercial BarTabs/ Sani-Tabs sanitizing solution. The solution must be warm. Let the parts soak at least one minute. 1. Daily, Rinse the unit after use. a. Rinse unit with warm water and empty completely. b. Fill unit with warm water. c. Open unit and empty contents completely. 2. Clean and sanitize the lid assembly. a. Remove lid from unit and submerse it in cleaning solution, cleaning thoroughly. b. Using the supplied brush, clean inside the filling tube. c. Rinse with clean water. d. Submerse in sanitizing solution for 5 minutes then air dry completely. 3. Cleaning and sanitizing body assembly. a. Pour a cleaning solution into the open server. With a sponge brush, thoroughly clean inside liner. b. Rinse the unit using a fresh water rinse. c. Fully fill unit with sanitizing solution. Allow to sit for 5 minutes then drain through the faucet. d. Remove faucet and gauge glass from unit and brush out with cleaning solution. e. f. With the faucet removed, clean the silicone elbow fitting (Tank to Faucet Tube). Use a tube brush soaked in cleaning solution, insert it through the faucet shank. Rinse by pouring water from inside the unit, allowing rinse water to flow into a sink until water runs clear. Wipe outside the outside surfaces of the unit with a moist clean cloth. g. Place the body assembly upside down on a rack to thoroughly air dry. 4. Cleaning the faucet parts. a. Unscrew the bonnet/handle assembly from the faucet and disassembly removing spring, seat cup and shaft. b. Clean and rinse parts. Place in sanitizing solution for 5 minutes, remove and air dry, 5. Assemble. a. When all pieces are completely dry, assemble the server. 12 Rough-In Drawing 13 Product Warranty Information The Wilbur Curtis Company certifies that its products are free from defects in material and workmanship under normal use. The following limited warranties and conditions apply: 3 Years, Parts and Labor, from Original Date of Purchase on digital control boards. 2 Years, Parts, from Original Date of Purchase on all other electrical components, fittings and tubing. 1 Year, Labor, from Original Date of Purchase on all electrical components, fittings and tubing. Additionally, the Wilbur Curtis Company warrants its Grinding Burrs for Forty (40) months from date of purchase or 40,000 pounds of coffee, whichever comes first. Stainless Steel components are warranted for two (2) years from date of purchase against leaking or pitting and replacement parts are warranted for ninety (90) days from date of purchase or for the remainder of the limited warranty period of the equipment in which the component is installed. All in-warranty service calls must have prior authorization. For Authorization, call the Technical Support Department at 1-800-995-0417. Effective date of this policy is April 1, 2003. Additional conditions may apply. Go to www.wilburcurtis.com to view the full product warranty information. CONDITIONS & EXCEPTIONS The warranty covers original equipment at time of purchase only. The Wilbur Curtis Company, Inc., assumes no responsibility for substitute replacement parts installed on Curtis equipment that have not been purchased from the Wilbur Curtis Company, Inc. The Wilbur Curtis Company will not accept any responsibility if the following conditions are not met. The warranty does not cover and is void under the following circumstances: 1) Improper operation of equipment: The equipment must be used for its designed and intended purpose and function. 2) Improper installation of equipment: This equipment must be installed by a professional technician and must comply with all local electrical, mechanical and plumbing codes. 3) Improper voltage: Equipment must be installed at the voltage stated on the serial plate supplied with this equipment. 4) Improper water supply: This includes, but is not limited to, excessive or low water pressure, and inadequate or fluctuating water flow rate. 5) Adjustments and cleaning: The resetting of safety thermostats and circuit breakers, programming and temperature adjustments are the responsibility of the equipment owner. The owner is responsible for proper cleaning and regular maintenance of this equipment. 6) Damaged in transit: Equipment damaged in transit is the responsibility of the freight company and a claim should be made with the carrier. 7) Abuse or neglect (including failure to periodically clean or remove lime accumulations): Manufacturer is not responsible for variation in equipment operation due to excessive lime or local water conditions. The equipment must be maintained according to the manufacturer’s recommendations. 8) Replacement of items subject to normal use and wear: This shall include, but is not limited to, light bulbs, shear disks, “0” rings, gaskets, silicone tube, canister assemblies, whipper chambers and plates, mixing bowls, agitation assemblies and whipper propellers. 9) Repairs and/or Replacements are subject to our decision that the workmanship or parts were faulty and the defects showed up under normal use. All labor shall be performed during regular working hours. Overtime charges are the responsibility of the owner. Charges incurred by delays, waiting time, or operating restrictions that hinder the service technician’s ability to perform service is the responsibility of the owner of the equipment. This includes institutional and correctional facilities. The Wilbur Curtis Company will allow up to 100 miles, round trip, per in-warranty service call. RETURN MERCHANDISE AUTHORIZATION: All claims under this warranty must be submitted to the Wilbur Curtis Company Technical Support Department prior to performing any repair work or return of this equipment to the factory. All returned equipment must be repackaged properly in the original carton. No units will be accepted if they are damaged in transit due to improper packaging. NO UNITS OR PARTS WILL BE ACCEPTED WITHOUT A RETURN MERCHANDISE AUTHORIZATION (RMA). RMA NUMBER MUST BE MARKED ON THE CARTON OR SHIPPING LABEL. All in-warranty service calls must be performed by an authorized service agent. Call the Wilbur Curtis Technical Support Department to find an agent near you. 7/7/11@10.6 . EDR 7851 WILBUR CURTIS CO., INC. 6913 Acco St., Montebello, CA 90640-5403 USA Phone: 800/421-6150 Fax: 323-837-2410 Technical Support Phone: 800/995-0417 (M-F 5:30A - 4:00P PST) Web Site: www.wilburcurtis.com E-Mail: techsupport@wilburcurtis.com 7/11 . F-3806 rev NC